Inflatable bolster

ABSTRACT

This invention is in the field of safety devices to lessen injuries arising from impact in vehicles, particularly automobiles. A bolster which may be employed to reduce impact severity to passengers from either frontal or side impacts is activated by impact sensing devices. The housing of the bolster has a lateral length L. Upon activation, the bolster is inflated with an activating fluid and extends the lateral length L of bolster upon activation.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.12/422,389, filed Apr. 13, 2009, and published as U.S. PatentApplication Pub. No. 2009/0250915 on Oct. 8, 2009, which claims thebenefit of and priority to U.S. Provisional Patent Application No.61/044,294, filed Apr. 11, 2008. This application also is acontinuation-in-part of U.S. patent application Ser. No. 11/560,473,filed Nov. 16, 2006, and published as U.S. Patent Application Pub. No.2007/0108747 on May 17, 2007, which claims the benefit of and priorityto U.S. Provisional Patent Application No. 60/738,222, filed Nov. 17,2005. U.S. patent application Ser. No. 12/422,389 is acontinuation-in-part of U.S. patent application Ser. No. 11/560,473. Theentire contents of each of the foregoing applications and publicationsare hereby incorporated by reference.

FIELD OF THE INVENTION

This invention relates to the field of safety devices as are ofteninstalled in motor vehicles, particularly automobiles. Amongst manysafety devices that are installed in vehicles to lessen injuries arisingfrom impact are bolsters. A bolster may be part of an instrument panelin which case the bolster extends transversely to the vehicle. Bolstersmay also be used for side impact events in which case the length of abolster may extend longitudinally of the vehicle. Such bolsters may bemounted in door panels, side panels or roof panels of the vehicle.Bolsters can also be utilized in other locations and directions asdesired to lessen injuries arising from impact events.

BACKGROUND OF THE INVENTION

In the first instance, bolsters are designed with a design point ofimpact. The design point of impact is determined by assuming theposition of a statistical male or female occupant. Ideally, the vehicleoccupant is in a designated position and is using a seatbelt or othersimilar safety harness. However, because of the differentiation in sizeof the vehicle occupants and because not all vehicle occupants useseatbelts, and therefore the location of the occupant may not be asexpected, the point of impact between the occupant and the bolster mayoccur at other than the most desirable design location. Vehicles alsohave many other envelope constraints as to the amount of space availablefor mounting a bolster. In many cases, the vehicle mounting envelopeconstraints confine a bolster to a certain lateral length. It would bedesirable, however, that the bolster, when called upon to provide itssafety function, have a greater lateral length.

As used in this description and claims, the term “lateral” is used todescribe the transverse width of the bolster. If the bolster weremounted against an instrument panel, the lateral extent of the directionwould be transverse of the vehicle. If the bolster were mounted to adoor frame, the lateral extent of the bolster would extendlongitudinally of the vehicle. If the bolster were mounted on an angularsupport pillar such as an A pillar, the lateral length of the bolsterwould extend longitudinally and angularly of the vehicle. In short, theterm “lateral” is intended to encompass any mounting location of thebolster with regard to the vehicle.

In accordance with the information set out above, it would be desirable,if a bolster were able to increase its lateral extent upon activation.

Known in the art are the following patent and patent applications whichdisclose inflatable bolsters and the like: US 2007/0108747; U.S. Pat.No. 6,032,978; U.S. Pat. No. 6,203,057; U.S. Pat. No. 6,305,710; U.S.Pat. No. 6,517,103; U.S. Pat. No. 6,578,867; U.S. Pat. No. 6,619,689;U.S. Pat. No. 6,758,493; U.S. Pat. No. 6,848,715; U.S. Pat. No.6,976,706; U.S. Pat. No. 7,350,852; and WO 2006/132990.

SUMMARY OF THE INVENTION

In accordance with this invention, an inflatable bolster includes ahousing, the housing defines a substantially closed volume for receivingfluid under pressure. The bolster has a source of pressurizing fluid.The housing defines an occupant face and a mounting face. The housinghas a lateral length L in the direction substantially parallel to theoccupant face. The bolster comprises an extension structure forextending the lateral length L of the bolster upon pressurization of thebolster.

In accordance with another aspect of the present invention, aninflatable bolster for use in an occupant compartment of a vehicle isprovided, the inflatable bolster comprising an inflatable housing havinga mounting wall which is devised to mount to a reaction structure of thevehicle, an occupant wall which is opposite the mounting wall anddevised to face the occupant compartment, a substantially closed volumeformed between the mounting wall and the occupant wall, and arestriction means formed between the mounting wall and the occupant wallfor restricting fluid flow between different areas of the housing. Theinflatable bolster also comprises a source of pressurized fluid mountedto the housing and being in fluid communication with the substantiallyclosed volume for inflating the housing.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will be better understood, upon review of the attacheddrawings which illustrate various embodiments in accordance with theinvention.

FIG. 1 illustrates an isometric view of a bolster in accordance with theinvention which incorporates alternate first and second embodiments ofthe invention;

FIG. 2 illustrates an isometric view of the un-deployed configuration ofthe left end of the bolster of FIG. 1;

FIG. 3 illustrates an isometric view of the deployed configuration ofthe structure illustrated in FIG. 2;

FIG. 4 illustrates a cross-section of the bolster of FIG. 1 taken alongline 4-4;

FIG. 5 is a similar cross-section to FIG. 4 showing the bolster of FIG.4 in deployed configuration;

FIG. 6 is a plan view of the deployed bolster of FIG. 5;

FIG. 7 is a perspective view of the structure of the right-hand end ofthe bolster of FIG. 1 in the un-deployed configuration;

FIG. 8 illustrates in perspective view the structure of FIG. 7 in thedeployed configuration;

FIG. 9 illustrates a perspective view of a bolster in accordance withthe invention which incorporates a third embodiment of the invention;

FIG. 10 is a front view of the bolster shown in FIG. 9;

FIG. 11 is a sectional view taken along line AA as shown in FIGS. 9 and10;

FIG. 12 is a sectional view taken along lines BB shown in FIGS. 9 and10;

FIG. 13 is a sectional view along line CC illustrated in FIGS. 9 and 10;

FIG. 14 illustrates an isometric view of a bolster in accordance withthe invention which incorporates a fourth embodiment of the invention;

FIG. 15 is a front view of the bolster of FIG. 14;

FIG. 16 is a sectional view along line DD of FIGS. 14 and 15;

FIG. 17 illustrates a perspective view of a bolster in accordance withthe invention which incorporates a fifth embodiment of the invention;

FIG. 18 is a sectional view taken along lines EE and FF shown in FIG.17;

FIG. 19 illustrates a perspective view of a bolster in accordance withthe invention which incorporates a fifth embodiment of the invention;

FIG. 20 is a sectional view taken along lines GG and HH shown in FIG.19;

FIG. 21 illustrates a perspective view of a bolster in accordance withthe invention which incorporates a sixth embodiment of the invention;

FIG. 22 is a sectional view taken along line II shown in FIG. 21;

DETAILED DESCRIPTION OF THE INVENTION

Bolsters may be used to provide energy absorption to lessen injury inthe event of a vehicle/occupant impact. A bolster achieves the energyabsorption by filling the bolster with a pressurized fluid, usually agas, upon the occurrence of an impact event. Once the bolster is filledwith fluid, then energy is absorbed by releasing the fluid through anorifice of controlled size.

Some bolsters are described as active bolsters. An active bolsterdiffers from an inactive bolster in that the bolster moves relative toits support surface towards the occupant. By decreasing the distancebetween the occupant face of the bolster and the occupant, then agreater length of time may be used to slow the speed of the occupantrelevant to the speed of the vehicle and thus provide an opportunity forreduction of force in decelerating the occupant relative to the vehicle.The invention of the present application may be utilized with eitheractive or inactive bolsters.

Typically bolsters are pressurized by a source of gas which may becontained in a cartridge. The gas may be released by initiators whichmay be linked to various vehicle sensors. The vehicle sensors may sensea vehicle impact which may be in the nature of an excessivedeceleration, as may be typical in frontal impacts of moving vehicles, arapid vehicle acceleration as may be involved in a rear impact, vehiclelateral acceleration as may be involved in impacts from either side ofthe vehicle or impending vehicle rollover. In all cases, when such avehicle event occurs, there develops a relative velocity between thevehicle and the occupants riding in the vehicle. The occupants may thenstrike vehicle structure and the purpose of the bolster is to reduce theforces involved so as to lessen injury.

FIG. 1 illustrates a bolster generally at 10. The bolster has a mountingface 12 and an occupant face 14, visible in FIG. 4. The bolster 10includes an extension structure 16 located at the left hand end ofbolster 10 and extension structure 18 located at the right hand end ofbolster 10. While bolster 10 has been illustrated as embodying the twoextension structures 16 and 18 respectively, it will be recognized thatin accordance with this invention, a bolster may use any combination ofone or more of extension structures 16 and 18. Thus, a bolster mayutilize one such extension structure 16 or two or more extensionstructures 16. Similarly, a bolster may involve one extension structure18 or two or more extension structures 18. A bolster may have anycombination of one or more of the two extension structures.

In accordance with this embodiment of this invention as illustrated inFIG. 1, the bolster is a unitary structure. Being a unitary structure,the bolster is preferably made by a blow molding procedure. The bolsterincludes a housing 20. The housing defines the occupant face 14 and themounting face 12. The housing defines a substantially closed volume 22.The volume 22 is described as substantially closed in that the volume isintended to confine the pressurizing gas when the bolster is activated.The housing will thus either define an inlet for pressurized gas orpressurized gas will be stored in a preactivation cylinder within thehousing. The housing will also define one or more exhaust apertures topermit release of gas during the energy absorption phase.

As shown in the un-deployed stage, the housing defines a lateral lengthL extending in the direction which is substantially parallel to theoccupant face.

It will be understood that upon activation, fluid will fill the closedvolume of the bolster. In the embodiment illustrated in FIG. 1, thebolster also includes expansion facilitating structure 30. This allowsthe bolster to be an active bolster so that the occupant face will movetoward the occupant to assist in reduction of forces experienced by theoccupant on contacting the bolster. In the particular exampleillustrated in FIG. 1, the expansion facilitating structure 30 comprisestwo vertically extending pleats 32 and 34 and a laterally extendingpleat 36. The effect of these pleats during deployment will be discussedbelow.

Focusing now on the left hand end of the structure, in FIG. 1, thehousing 20 includes a main portion 21 and an auxiliary portion 40. Theextension structure 16 comprises in part the auxiliary portion 40. Theauxiliary portion 40 is an integral part of the housing 20 and is also ahollow structure. The auxiliary portion 40, extends away from theoccupant face 14 in a direction which is substantially perpendicular tothe dimension L. The auxiliary portion 40 has a length L₁ as illustratedin FIG. 4. Upon deployment of the bolster, the auxiliary portion 40moves hingedly relative to the main portion 21 to extend the laterallength L of the bolster 10 by an amount substantially equal to L₁thereby providing a laterally enlarged bolster for use during thedeployment phase. The extension structure 16 also includes an expandablearea 42. The expandable area 42, preferably includes at least one pleat44. The expandable area 42 is formed at the intersection of the mountingface 12 and an inner face 46 of the auxiliary portion 40. Expansion ofthe expandable area 42 and the pressurization of the auxiliary portion40 in conjunction with pressurization of the main portion causes theauxiliary portion 40 to move hingedly to the deployed position as shownin FIG. 6. As the auxiliary portion 40 moves hingedly relative to themain portion 21, the corner 50 where the auxiliary portion 40 meets withthe occupant face of the main portion 21, distortion will occur,although the apex may remain as is shown diagrammatically at 52 in FIG.6. In addition, the uppermost surface 54 of the auxiliary portion 40 mayalso deform upwardly under the effect of the pressurizing fluid.

Focusing now on the right hand end of the bolster 10 as illustrated inFIG. 1, reference is made to FIGS. 7 and 8. The extension structure 18in this embodiment, is illustrated in an end face 60 of the housing 20.The end face 60 includes an end face wall 62 which comprises theoccupant face 14 of the bolster 10. Additionally, the end face 60includes a mounting wall face 64, which coincides with the mounting face12. In the embodiment illustrated, the extension structure 18 includesan expandable area 70. The expandable area advantageously includes atleast one first pleat 72.

As shown in FIG. 7, the expandable area 70 is in the form of at leastone pleat 72 which extends internally into the closed volume 22 of thebolster 10. Upon activation of the bolster, the pressurized fluid,pushes the pleat 72 out, relative to the end face 60, where the pleat isable to expand to the position shown in FIG. 8. The pleat 72, havingextended externally of the housing 20 now provides an additional lengthL₂ to the bolster for use in energy absorption on contact with a vehicleoccupant (see FIG. 8).

Preferably, the bolster 10 is made in a blow molding operation. In blowmolding, a parison is extruded, the parison is enclosed in a blow moldstructure, and a blowing gas is injected into the interior of theparison. Upon expansion of the parison, the parison then expands so asto obtain the shape of the mold cavity. Generally speaking, the wallthickness of the parison is relatively uniform throughout the expandedparison subject to the necessity of plastic flow to obtain the shape asdefined by the mold. In the blow molding process, slides can beestablished in the mold. The term “slide” is used to describe astructure that is used to move from a withdrawn position (usually not inthe mold cavity) to an extended position, before the parison has cooled.By extending the slide, which effectively moves the slide against thewall of the parison, the wall of the parison is stretched to moveinwardly of the mold surface. Thus, use of a slide may be used to createthe at least one pleat 72 in connection with the extension structure 18and to locate that structure so that it extends internally of thehousing 20. The use of the slide does not, however, rupture the wall ofthe parison. Thus the finished product can still remain as a housingdefining a substantially closed volume. Use of the slide, will create adiminution of the thickness of the wall of the parison, this helps tocreate a relatively thinner wall, which is then capable of undergoingthe movement between the un-deployed and deployed configurationsillustrated in FIGS. 7 and 8 without rupture of the wall of the housing.To facilitate movement of this type, the plastic used for the parisonmay be selected from the group of suitable materials including by way ofexample thermoplastic olefins or a plastic available from SalflexPolymers under the trade mark SALFLEX 245™.

Similarly, the extension structure 16 illustrated in FIGS. 1 through 4may be formed by the use of slides in a blow mold. The auxiliary portion40 can be readily formed in the blow mold. The expandable area 42 andthe at least one pleat 44 can be created in the blow mold by use of aslide which moves some of the parison wall internally of the mold cavityto create the structure upon cooling, as shown at the left hand end ofFIG. 1. This process also is capable thus of creating an expandable areawhile ensuring that the housing still remains with a substantiallyclosed volume.

As shown in FIG. 1, the bolster 10 is what is referred to as an activebolster. Thus, rather than simply pressurizing the bolster and using thepressurized thickness of the bolster for energy absorption, it isdesirable that the occupant face extend outwardly toward the occupant.The pressurization of the bolster may itself distort the bolster so thatthe bolster achieves a more rounded configuration than the un-deployed,substantially rectangular configuration illustrated in the embodimentshown in FIG. 1. However, in order to facilitate further movement of theoccupant face relevant to the mounting face, the bolster 10 may alsoinclude the expansion structure 30. The expansion structure 30 caninclude second pleats to facilitate such expansion. The pleats may bemade by use of slides or by initial configuration of the mold dependingupon the location of the mold parting lines and the configuration of themold cavity. Most preferably as shown in FIG. 1, the expansionstructure, includes the generally vertically extending pleats 32 and 34as well as the longitudinally extending pleat 36. By providing at leastone pleat and preferably a series of pleats, the bolster may deformoutwardly relative to the mounting face 12.

As shown in FIG. 4, the mounting face 12 will be mounted against asuitable support or reaction structure illustrated generally by thedotted line 80. As shown in FIG. 5, it is assumed there is no relativemovement of the reaction surface 80. Thus, deformation of the expandablestructure 30, as well as general deflection of the wall of the housing,means that the housing 20 will form a substantially sausage shape. Aswell, the general deflection of the wall of the housing, means that thehousing 20 will form a substantially sausage shape as shown in FIG. 5.As shown, the occupant face 14 is no longer necessarily planar but ismoved effectively closer to the occupant. This provides a greaterdistance for energy absorption before the occupant comes into contactwith the mounting surface 80. As shown in FIG. 6, the auxiliary portion40 has hingedly moved relative to the main portion by expansion of theexpandable area 42 through expansion of the at least one pleat 44.

FIG. 9 illustrates, in perspective, an alternative embodiment of theinvention. In FIG. 9, the bolster shown generally at 100 includes amounting face 112 and an occupant face 114. The bolster 100 is an activebolster and includes an extension structure 116 located at the left handend of bolster 100 as illustrated in FIG. 9. The bolster 100 includes ahousing 120. The housing 120 defines a substantially closed chamber 122.In many respects the bolster 100 is similar to the bolster 10illustrated in FIG. 1.

The bolster 100 includes a main portion 121 and an auxiliary portion140. The extension structure 116 comprises in part the auxiliary portion140. The auxiliary portion 140 is an integral part of the housing 120and is also a hollow structure. The auxiliary portion 140 includes anauxiliary chamber 123.

The extension structure 116 also includes an expandable area 142. Theexpandable area 142 preferably includes at least one pleat 144. In thisrespect, the embodiment illustrated in FIG. 9 operates similar to theembodiment illustrated in FIG. 1.

The principal difference between these two embodiments however is theability to change the rate at which the activating fluid flows into theauxiliary chamber 123. The source of inflating fluid to cause activationof the bolster is first directed to the chamber 122 in main portion 120.To control the rate of flow of activating fluid from the main portion tothe auxiliary portion, a restriction means including a limited flow pathis provided. In this example, the expansion structure 116 includes ahollow rib 117. The rib 117 is defined by slides which may be activatedduring the blow molding manufacturing process by setting out depressedareas 119 on either side of the rib. As shown in FIGS. 11, 12 and 13,the hollow rib 117 is formed by slides which move the mounting face 112against the interior of the occupant face 114. This provides a channel121 for flow of fluid from the chamber 122 within the main portion 120to the auxiliary chamber 123 within the auxiliary portion 140. Also, asshown in this embodiment the rib 117 is itself in the form of a bellowsso as to not restrict the desired movement of auxiliary portion 140relative to main portion 121. By selection of the number of ribs 117 andthe sizing of those ribs, the inflation characteristics of the auxiliaryportion 140, can be controlled by the designer.

It is preferred that in operation, particularly with respect to anactive bolster, that the main portion of the bolster first begin tomodify its position relative to the vehicle occupant before movement ofthe auxiliary portion 140 to the deployed position. By providing arelatively restrictive flow path using at least one such rib 117, thedeployment timing of the auxiliary portion 140 can be selected asdesired. Any number of ribs 117 having any particular size of flowchannel or configuration may be utilized. By using at least one suchrib, it is possible to obtain what is, in effect, a slightly delayeddeployment of the auxiliary portion 140 relative to the time that themain portion 121 begins its deployment upon activation.

FIG. 14 illustrates a further embodiment and illustrates a bolster 200.The bolster 200 is similar to the bolster 100 except that the extensionstructure 216 is provided to activate the movement of the auxiliaryportion 240 relevant to the main portion 220. In this case, theextension structure 216 includes an expandable area 242 which includesat least one pleat 244. In this case the pleat 244 has a centraldepressed portion 245, together with two grooves 247 which define thepleat 244.

As shown in FIG. 16, the depressed areas 247 and 245 constitutetherebetween, a pair of ribs 249 which extend vertically upwardly, asshown in FIG. 14. This in turn defines a pair of conduits 249, eachconduit having internally thereof a flow path 251. Because the depressedareas 247 do not extend all the way to the lower edge of the pleat 244as shown in FIGS. 14 and 15, there is a flow path for activating fluid,firstly from the main portion 220 to the first rib 249, verticallyupwardly through the first flow path 251 and then horizontally acrossthe upper edge, as illustrated in FIGS. 14, and 15 and then downwardlythrough the second flow path 251 where it may then enter into theauxiliary portion 240. Thus, the pleat 244 provides a serpentine pathflow. This serpentine path flow by its length and cross-sectional sizeconstitutes a restriction means which can also be used to provide asomewhat restricted flow and thus a slightly delayed deployment of theauxiliary portion 240 upon application of activating fluid to the mainportion 220.

Either of the bolsters 100 or 200 illustrated in FIGS. 9 through 13 and14 through 16 respectively, may be fitted with similar structures on theright hand end as depicted, or structures similar to structure 18 asdiscussed in association with the bolster of FIG. 1. It will also bepossible to vary the number and location of the various flow channels toachieve the desired activation time delay as may be considereddesirable.

FIG. 17 illustrates, in perspective, an alternative embodiment of theinvention. In FIG. 17, the bolster shown generally at 300 comprises ahousing 302 which includes a mounting wall 304 and an occupant wall 306which is opposite thereto. The mounting wall 304 comprises an exteriormounting face 308 which, when installed, faces the reaction structure ofthe vehicle. The occupant wall 306 comprises an exterior occupant face310 which, when installed, faces the vehicle interior and any occupantstherein.

As shown in FIG. 18, a substantially closed volume 310 is formed betweenthe mounting wall 304 and the occupant wall 306. The bolster 300 furthercomprises a source of pressurized fluid 312 which is mounted to thehousing 302 and, as discussed above, serves to inflate the bolster 300by injecting pressurized fluid into the volume 310, In the illustratedembodiment, this source 312 is a cartridge.

The housing 302 comprises a first and a second restriction means 314 aand 314 b formed between the mounting wall 304 and the occupant wall 306for restricting the flow of the fluid injected by the source 312. Therestriction means 314 a and 314 b restricts the fluid flow betweendifferent areas 316, 320 a and 320 b of the housing 302.

Similar to the hollow rib 117 of FIGS. 9 to 13 and the pleat 244 ofFIGS. 14 to 16, the restriction means 314 a and 314 b separate thehousing 302 into a main chamber 316 into which the source 312 injectspressurized fluid and respective auxiliary portions 320 a and 320 b.

In the embodiments illustrated, the restriction means 314 a and 314 bboth comprise depressed areas 314 a and 314 b, similar to the depressedarea 119 of FIGS. 9 to 13 and the depressed areas 245 and 247 of FIGS.14 to 16. These areas 314 a and 314 b are preferably formed duringmolding of the housing 302 and formed by compressing the mounting wall304 until it meets the occupant wall 306 such that once molded the twowalls 304 and 306 are in contact. It will be appreciated however thatthe occupant wall 306 could similarly be compressed into the mountingwall 304. The depressed areas 314 a and 314 b are sealingly bondedtogether in order to prevent air from seeping through.

In the embodiment illustrated, the depressed area 314 a does not extendthe entire width of the housing. The depressed area 314 a comprises achannel 322 at the end 324 which connects the main chamber 316 with theinterior of the auxiliary portion 320 a, which here forms a hollowauxiliary chamber 318 a. During deployment of the bolster 300, fluidflows from the source 312, into the main chamber 316, through thechannel 322 and into the auxiliary chamber 318 a.

As before, by forcing the pressurized fluid through the channel 322, therate at which the fluid enters the auxiliary chamber 318 a, and hencethe rate of inflation of the auxiliary chamber 318 a, will differ fromthat of the main chamber 316. In particular, choking the fluid flow atthe channel 322 can enable a slightly delayed deployment of theauxiliary portion 320 a. By varying the diameter and shape of thechannel 322, the relative rates of inflation of the main and auxiliarychambers 316 and 318 a can be adjusted.

It will be appreciated that, in contrast with the auxiliary portions ofthe previous figures, the auxiliary portions 320 a and 320 b are notprovided with an extension structure.

In the embodiment illustrated, auxiliary portion 320 b consists of thedepressed area 314 b. In other words, the portions of the mounting wall304 and the occupant wall 306 which form the auxiliary portion 320 bhave been compressed and no fluid can travel in or out thereof. As such,the auxiliary portion 320 b will not inflate. It will be appreciatedthat such a non-inflating portion of the bolster 300, whose occupantface 310 may be subject to various additional esthetic and/or packagingconstraints, advantageously enables a variety of design options whichmight not be available given a conventional bolster whose entire housingwas inflated.

FIGS. 19 and 20 illustrate another embodiment of the invention which issimilar to that of FIGS. 17 and 18. As before, a bolster 400 similarlycomprises a housing 402 formed by a mounting wall 404 and an occupantwall 406, which surround a substantially closed volume 410 therebetween.The housing 402 is divided by restriction means 414 a and 414 b, whichhere comprise depressed areas 414 a and 414 b, into a main chamber 416and two auxiliary portions 420 a and 420 b.

In the embodiments illustrated, and in contrast with the equivalentelements in FIGS. 17 and 18, the depressed area 414 a extends the entirewidth of the housing 402, such that both ends 424 of the depressed area414 a engage the lateral side 426 of the housing 402. Therefore, thereis no channel formed by the depressed area 414 a between the main area416 and the auxiliary chamber 418 a formed by the auxiliary portion 420a. The auxiliary chamber 418 a is isolated as there is little to nofluid communication between it and the main chamber 416. As such,auxiliary portion 420 a will not inflate.

The auxiliary portion 420 b is equivalent to the auxiliary portion 320b.

FIGS. 21 and 22 illustrate another embodiment of the invention. Asbefore, a bolster 500 similarly comprises a housing 502 formed by amounting wall 504 and an occupant wall 506, which enclose asubstantially closed volume 510 therebetween. The housing 510 is dividedby a restriction means 514, which here comprises a semi-circulardepressed area 514, into a main chamber 516 and an auxiliary portion andchamber 520 and 518.

In this embodiment, the distance between the mounting wall 504 and theoccupant wall 506 is locally decreased by the depressed area 514, thatis to say the portions of the mounting wall 504 and the occupant wall506 at the depressed area 514 are closer to each other than in the mainchamber 516 and the auxiliary chamber 518. The walls 504 and 506 havenot been completely compressed and are therefore not in contact. Assuch, it will be appreciated that the depressed area 514 only partiallyblocks fluid flow thereacross. However, such a decrease willnevertheless have an effect on the relative inflation rates of the mainand auxiliary chambers 516 and 518.

A pair of channels 522 is formed between either end 524 of thesemi-circular depressed area 514 and the lateral side 526 of the housing502. The magnitude of the local decrease in the distance between themounting wall 504 and the occupant wall 506 caused by the depressed area514, in addition to the diameter and shape of the channels 522, willdetermine the relative inflation rates of the main and auxiliarychambers 516 and 518.

It will further be appreciated that an alternate channel could beprovided which increases the local distance between the mounting wall504 and the occupant wall 506 and may thereby increase flow to a givenarea.

In accordance with some of the embodiments illustrated and describedherein, it will be recognized, that a bolster has been provided havingan un-deployed length L measured in a direction referred to as thetransverse direction. Upon deployment, utilizing either of theembodiments as described herein, the bolster may gain an additionallength in that transverse direction by expansion of an extensionstructure to provide increased lateral length. The orientation of thebolster may be selected as desired by the vehicle designer and thus thedirections, vertical and horizontal are given only by way ofillustrative example and not by limitation. In fact, the bolster may beactive or inactive and may be located in the vehicle as desired and inany orientation desired.

In accordance with some of the embodiments illustrated and describedherein, it will further be recognized that a bolster has been providedhaving an auxiliary chamber with different deployment timing and orcharacteristics from that of a main chamber. In particular, as describedherein, a restriction means and flow channel may be provided whichrestricts fluid flow to the auxiliary chamber, thereby delayingdeployment. Alternatively, as described herein, a restriction means maybe provided which blocks fluid flow to the auxiliary chamber entirely,thereby providing a portion which will not inflate when the bolster isdeployed.

In accordance with the embodiments illustrated and described herein, itwill be recognized, that a bolster has been provided having anun-deployed length L measured in a direction referred to as thetransverse direction. Upon deployment, utilizing either of theembodiments as described herein, the bolster may gain an additionallength in that transverse direction by expansion of an extensionstructure to provide increased lateral length. The orientation of thebolster may be selected as desired by the vehicle designer and thus thedirections, vertical and horizontal are given only by way ofillustrative example and not by limitation. In fact, the bolster may beactive or inactive and may be located in the vehicle as desired and inany orientation desired.

All descriptions and illustrations contained herein are to be taken byway of example only and reference shall be made to the claims for thefull scope and extent of the invention.

1. An inflatable bolster, said bolster comprising a housing, said housing defining a substantially closed volume for, during pressurization, receiving a fluid under pressure, said bolster having a source of the fluid under pressure, said housing defining an occupant face and a mounting face, said housing having a lateral length L in the direction substantially parallel to said occupant face, wherein said bolster comprises at least one extension structure for extending the lateral length L of said bolster upon pressurization of said bolster.
 2. The bolster of claim 1 wherein said bolster is a unitary structure.
 3. The bolster of claim 2 wherein said bolster is blow molded.
 4. The bolster of claim 1 wherein said at least one extension structure comprises at least one expandable area and said lengthening of said lateral length L occurs, at least in part, by expanding said expandable area.
 5. The bolster of claim 4 wherein said expandable area includes at least one first pleat.
 6. The bolster of claim 5 wherein said expandable area is located adjacent an end face of said bolster.
 7. The bolster of claim 6 wherein said at least one first pleat is located on said end face and extends internally of said housing prior to said pressurization and extends externally of said housing after said pressurization.
 8. The bolster of claim 4 wherein said housing comprises a main portion and at least one auxiliary portion, said main portion defining said lateral length L and said auxiliary portion comprising, at least in part, said extension structure.
 9. The bolster of claim 8, wherein said auxiliary portion extends away from said occupant face.
 10. The bolster of claim 9 wherein said expandable area is positioned between said main portion and said auxiliary portion, and wherein said auxiliary portion moves hingedly relative to said main portion about said expandable area upon said pressurization.
 11. The bolster of claim 10 wherein said expandable area includes at least one first pleat.
 12. The bolster of claim 11 wherein said at least one first pleat is located so that upon pressurization of said housing, said pleat facilitates said hinged movement of said auxiliary portion.
 13. The bolster of claim 8 wherein said bolster comprises a plurality of said auxiliary portions.
 14. The bolster of claim 6 wherein said bolster comprises a second extension structure adjacent a second end face of said bolster.
 15. The bolster of claim 8 wherein said bolster further includes flow restriction means for permitting flow of pressurization fluid from said main portion to said auxiliary portion.
 16. The bolster of claim 15 wherein said flow restriction means includes at least one hollow rib.
 17. The bolster of claim 16 wherein said at least one rib extends generally transversely of said bolster.
 18. The bolster of claim 16 wherein said restriction means defines a flow path which is serpentine.
 19. The bolster of claim 18 wherein said first expandable area includes at least one first pleat and said flow path extends along said pleat.
 20. The bolster of claim 7 wherein on said pressurization, said occupant face is pushed away from said mounting face by expansion of said substantially closed volume by the fluid under pressure.
 21. The bolster of claim 20 wherein on said pressurization, a portion of said substantially closed volume containing said at least one first pleat expands to increase a cross-sectional flow area of said fluid under pressure impinging on said at least one first pleat.
 22. The bolster of claim 20 wherein said end face comprises an end face wall adjacent said occupant face, and a mounting face wall adjacent said mounting face; said pleat defines a base area extending between said end face wall and said mounting face wall; and said base area increases on said pressurization, as said occupant face is pushed away from said mounting face by expansion of said substantially closed volume by the fluid under pressure.
 23. The bolster of claim 20 wherein said pleat comprises a tip opposite the base area, said tip extends a distance L₂ from said base area after said pressurization, said pleat defines a variable cross-sectional area parallel to said base area moving from said base area to said tip, and said variable cross-sectional area diminishes moving from said base area to said tip such that an exterior surface of said pleat is tapered. 